Method op treating metals



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mnnnnm I n. H. BULLEY. METHOD OF TREATING METALS. 7 APPLICATION FILED APR- 24, 1916- RENEWED AUG 5, 1919.

1,347,838 Patented July 27, 1920.

I //,000 Via/ts V I UNITED STATES PATENT 'ol rlca REGINALD n, BULLEY, 01 SYRACUSE, NEW YORK.

I METHOD OF TREATING METALS.

Specification of ltetters Patent. Patented l 27 1920 Application filed April 24, 191s, serial No. 93,070. Renewed August 5,;1919. Serial No. 315,567.

To all'whom it may concern:

Be it known that I, REGINALD H. Bummer,

a citizen of the United States, residing at lwhic the' following is a specification.

This inventionv relates to a method of treatirig metals by theme of an electric arc." ore particularly .it has to do with a method oftreating, melting and refining "metals and metallic alloys.

One of the objects of my invention is to overcome, the difficultiesexperienc'ed in actual practice with the, use of theelectric arc in existing types of electric furnaces,

and more particularly. those in which the basic process of refining iron and steelis carried out. With certain of the; electric metal refining furnaces gfthe electric arc type, which are now in use, it has been found 'advisable to introduce into the furnacethe metal in" a molten condition, in viewof the fact that the relationship of the arc electrodes and construction of the furnace generally do not seem to lend themselves efii-- ciently and economically to the' melting of the metal from itssolid state. For exam le,

3 0, with the Heroult type of electric arc urnace, it has been found advisable, in order to operate it at all economically on basic steel process, to introduce metal in the molten state into the furnace and then subject it. to the influences of an electric arc ofa comparatively low volta e. This voltage substantially limits the ength of the arc, and a current of relatively high amperage is initiall required properly to refine the bath in the urliace. After the metal in the Heroult furnace is'treated with a current of high amperage and relatively low volta e.

for the requlred period of time, then t e value of current flowin This type of furnace has been found to be relatively slow in operation and to be uneconomical in current consumption unless the metal is introduced into it in the molten state, as abcye stated. Heretofore, in order to'overcome some of the ob ections to the Heroult type of electric arc mace,

had been subjected to the influence of the is materially reduced, the 'voltageremaming substantially the same'as it was at the beginning of the process.

longcr and of hi her voltage than that used eroult, and urther that after the metal relatively longer arc of relatively hi her. voltage for a given time, the kilowatt oad of the workcircuit including the electric arc should be reduced; With this'latter type of furnace in actual practice it has been found that the meltin capacity is materially increased over that o the Heroult type, but other difficulties have been encountered with it, not present. in the Heroult type." For example, with a relatively longer are of com-' paratively' high volta' e,- undesirable heat.- mg and meltin of t e cover or top and lining of the si e walls of the furnace has been experienced, j and when. the kilowatt load was droppe'd,-the refiningaction of the furnace was not satisfactory'and particularly was this true .with' various metallic alloys of iron and steel. 1

With .myim roved process the objection I and increasing the length of the are, or by.

varying the kilowatt load of the'work circuit, either or both, are also overcome, and in addition thereto my invention provides for more efficient and economical refining than results from the use-of any of the earlier typesof electric arc furnace for metal melting and refining purposes of which I am aware.

A further object of my invention is toprovide a process with which it is possible readily to make the various steps essential to carrying itout, in a simple, efficient and "economical manner, it being possible for one skilled in the art to accomplish such regulation promptly at will, and substantially automatic regulation likewise being possible.

My improved process consists in subjecting the metal or metallic alloy to be treated to theinfluence ofan electric are having a substantially predetermined voltage in an electric circuit of given kilowatt load. The metal at the beginning of this first step may be either in molten, semi-molten or solid state, but ifthe predetermined voltage is sufficiently high, say two hundre'd volts, for iron, and the arc is sufiicientlylong, it will undoubtedly prove to be most efficient under all circumstances to start with the metal in solid state. The treatment of the metal under the influence of the electric are as prescribed by this first. step may be continued the required period of time to get the desired results, depending upon the nature of the metal or metallic alloy and the productsought. During this step the kilowatt -load of the cir'cuitmay be keptsubstantially constant in any well known manner. However, during this first step the conditions within the furnace and thenature of the metal or metallic alloy may be such as to require for .the proper carrying out of the process,'less heat than the initial kilowatt load of the circuit would cause to be r'adiated within the furnace, and I therefore provide for regulating within reasonable limits the kilowatt load during this first step.

. Next, I reduce the voltage of the workcircuit containing the electric. arc -whi le maintaining the kilowatt load on the circuit substantially the same'as it was during the first step. This may be accomplished in any desired manner. I prefer in the making of this step to reduce the length of the are as compared with its length during the first step. This insures a most eflicient utilization of the energy of the circuit in the further heating and refining of the metalrbe- -ing treated, so that the timefactor in completing the 'refinin process will be materially reduced. y reducing the time necessary to complete the process the capacity of an electric furnace is of course materiallyincreased, and this is accomplished in my improved process with relatively ef- .ficient kilowatt hour consumption.

My improved process further contemplates the variation, as required by the conditions of the furnace and the metal or metallic alloys being treated, for regulation of the kilowatt load on the work circuit after the second step in my process has begun. This regulation may be effected in any well known manner; After the refining has been carried on to the desired extent, as determined in the well known manner to one skilled in the art, the metal may be poured shell 2, of insulating material, and top or roof 3. The insulating lining and top 3 may be of any desired composition capable of meeting the chemical, temperature and structural requirements of a furnace of this character. The electrodes within the furnace may be of any desired construction, number and disposition.- 4 is an electric terminal or conductor whichv extends up through'the bottom of the furnace and makeselectric contact with the metal to be treated, which metal constitutes the lower electrode, the upper. one 5 extends through the top of the -furnace and is adjustable. up

" and down relative to thelower electrode and the bottom of the furnace in any well known manner, as by means of a rackand pinion mechanism 5'. I prefer at the present time to make the electrode 5 of amor houscarbon or graphite, though any suita le composition of material will sufiice. When v the I metal is introduced into the furnace and contacts with the terminal 4, the. metal and the terminal 4 may be consideredtogether con; stitutingfthe' lower electrode, if desired;

. 6 represents diagrammatically -.a step. .down transformer, the primary winding 6' i of whichis connected in a well lmown manner with a suitable source ofelectricenergy, not shown. This transformer'may be rovided with any; desired number of secon ary windings 6?. -Eor the purpose. of illustration .I .have shown four such secondary windings. Each. of these secondary windings may be 'of-any desired characteristic so long as any combination of them will produce in the total secondary circuit the full kilowatt capacity of the primary winding .6, that is whensaid windings are connectedeither in series, series parallel or' parallel. a

7 represents diagrammatically a kilowatt regulator of any preferred construction suitably connected with operating mechanism .8 for the upper electrode 5, which operating mechanism may bean electric motor, suitably geared to the rack and pin- .ion mechanism 5', (chain reduction gearing being indicated in dotted lines)'.the operation of the kilowatt regulator 7 being such that when the kilowatts in the circuit'exceed the predetermined value for which the regulator is adjusted, the regulator will operate. .to connect the motor in circuit and raise the electrode 5 the required distance to bring the kilowatt load in the circuit back to the predetermined value, whereas when thekilowatt load in the circuit is less than the predetermined value, the regulator willoperate to actuate the motor so asto lower the electrode 5 until the kilowatt-load in the circuit has the predetermined value. 7

is a'series or current transformer, the function of which is to supply currentto the solenoid 7 which consists of a winding 7" connecting in series with the current transformer 7 and a winding 7 connected across the line to the electrodes in such a manner that the current flowing in this winding will. be proportional to the voltage with the coil 7 of the solenoid 7 by which the line to the electrodes is supplied. The coils 7 and 7 are so wound as to supplement each other, that isto say, that an increase of voltage across the line produces an increase of current flowing in 7 in the same direction that an increase ofcurrent in the line will roduce an increase in the secondary trans ormer 7 and winding 7 10 and 11 are magnetic switches, the circuits of which are subject to the control of' the master solenoid 7 the switch 10 serving to close the motor circuit so as to causev the motor armature to rotate in one direction, whereas theswitch 11 is adapted to close the circuit so as to cause the armature to rotate in the opposite direction. When the magnetic switch 10 is energized, the direction of flow of currentithrou h the field coil of the motor is indicated y full line arrows, whereas when the magnetic switch 11]. is

' energized to close the motor circuit, the 'div rection of flow of current through the motor field isindicated by dotted arrows.

The control .of the Voltage of the. total secondary circuit, including the circuit between the electrodes in the furnace, as provided, for by the transformer 6, may not under certain conditions of the furnace and characteristics of the metal being treated, flexible for obtaining the reand I have therefore -pro-,, vided for a urther regulation of the kiIo-.

watt load of the circuit which may be' effectedas desired, dependent upon the conbe sufficiently sults desire treated and the ith this object in ditions of .the .metal bein refining, results sou ht.

'view I have-provi ed a variable resistances -9 of any desired construction for the kilo-.-

watt regulator 7. This regulating resistance 9 serves to regulate the current flowing to unting off a portion thereof .asdetermin by the amount of resistance introduced in the shunt circuit. Since the current given by the series transformer is always proportional to the amount of current flowing throu hthe furnace, if it becomes necessary to ad ust the amount of current' passing through the furnace under given conditions,-

it is'most easily done by variating the resistance 9 andthereby changing the amount of current which flows through the solenoid for a givenamount of current in the line.

My improved method may be carried out in connection with the apparatus just described in the following manner: The metal or metallic alloy to be treated may be introduced into the hearth ofthe furnace in any well l'r'n'ownmanner and-in any desired condition. As previously stated, my method is peculiarly adapted for efficiently melting the metal from the solid state, but if desired, the metal may be introduced into the hearthin the molten state; The desired character and quantity of'slag or slag forming materials may be introduced into the furnace at this time or later during the processas desired. a

The coils of the secondary circuit preferably are first suitably connected in series.

Assuming that the-kilowatt capacity-of the source of supply is 800 kilowatts and that eachof the secondary windings is wound for fifty volts and has a capacity of 200 kilo.-

watts, at the beginning of the process these secondary coils are connected in series by any well known connecting devices, ('not shown), so that the voltage of the sec.-

ondary circuit will be 200volts and the -kilo-' watt load 800 kilowatts. In order tostart the are. between the' lower end of the electrode'5 .;and the metal, it may be necessary initially .-to depress the electrode 5 until the arc is established, whereupon the electrode 5 .is raised until the maximum kilo watt load of the circuitis established or substantiallyso, atwhich time the kilowatt regulator 7 maybe connected into thecircuit to assist in substantially maintain-- ing fairly constant the maximum kilowatt load on the circuit. At this time the length of the arc between the bottom of the electrode 5 and the top of the materialin the furnace being treated, may be considered to be about medium.

After proceeding with the voltage at 200 volts and the kilowatt load substantially 800 kilowatts for the period of time required to get the material being treated in the desired condition, as determined by the con.- dition of the furnace and nature of themetal beingtreated,"'I next lower the voltage of the working circuit, say to 100 volts,

maintaining, however, the kilowatt load of the circuit substantially the same as before, namely 800 kilowatts. With the apparatus illustrated in the drawings, this may be accomplished Y by connecting any pair of the secondary windings 6 in series and that pair in parallel with any other pair of the secondary windings, similarly connected, which connections may be made electrically in any well known manner (not shown). At this time the kilowatt regula tor 7 may require adjustment to'acc'ommodate it to the new voltage condition of the circuit in order. that it may maintain the kilowatt load of the circuit substantially the same as it was during the first step;

will be such as to radiate more heat to the bath than was the case when the arc was longer, the voltage higher and the current flowing in the circuit 0t less amperage. The shorter the arc, the farther it is relatively from the top ofhe furnace, and the less destructive is its .flect upon the top themass of the electrode itself cutting 01% the radiation of the heat from the 'arc to the top more'eflectively as the arc is shortened in length.

The a'ction'of the relativel lower voltage and shorter arc on the meta of the bath is continued until the refining has been carried on to the desired .point asdetermined by the character and nature of the material being treated and the results desired; during the course of this refining, it may be found advisable to vary the kilowatt load of-tlie circuit within .limits, and this may be accomplished by the operative operating the resistance 9 for effecting the action of the kilowatt regulator7. As much as sixty per cent. regulation 'in this particular may be found necessary;

It may. be found advisable in certain instances to still furtherreduce the voltage, say for example to' fifty volts without materially 'changin the kilowatt load of the work circuit. This may be accomplished by connecting four of the secondary windings 6' in parallel; in the work circuit and the adjustment of the electrode 5 and of the kilowatt regulator? to establish the requisite ar'c on the one hand and the adjustment I of the kilowatt regulator 7 on the other substantially to maintain the constant kilowatt load des1red. 1

Under certain .circumstances',--- 1t may be advisable to introduce into the workcircuit a reactance, the function of which will be to have a smoothing out or balancing action in the'work circuit. This may readily be accomplished as by connecting in the work circuit a reactance of any well known-construc- -tionindicated diagrammatically at 10 in the drawings; .This reactance 10 may be provided with regulating meanslO of any well known construction, also shown diagrammatically, for varying its capacity as desired. The same results, of course, could be obtained by connecting in thework circuit a suitable resistance, but the energy losses due thereto would be objectionable and disadvantageous as compared with those incident to the use of the reactanoe just referred to.

To those skilled in the art of making apparatus of the class described, many modifications-of and widelv differing embodiments and applications of my invention will sug-- gest themselves, without departing from the spirit and scope thereof. My disclosures and descriptions are purely illustrative and are not intended to .be in any sense limiting.

What I claim is: i

1. The method of treating metal by the use of an electric are, which consists in subjecting the metal to the influence of a relatively high voltage electric arc. in an electric circuit of given kilowatt load, and then reducing the. voltage of said are in said circuit while retaining substantially the same kilowatt load.

2. The method oftreating metal by the use of an electric arc, which consists in subjecting the metal'tothe influence of a -rela-' tively high voltage electric arc in an electric circuit of given kilowattload,- maintaining the kilowatt load of said circuit .substan 8 5 tially constant, and then reducing the volt-- age of said are in said circuit while retaining substantially the same kilowatt. load. J

3. The method of treating metal by the.

use of an electric are, which consists in subducing the voltage of said are in said circuit while retaining fsubstantiall the same kilowatt load, maintaining the ilowatt load of the circuit during said last' described step substantially constant.

4. The method f treating metal by the use of an electric arc, which consists in Subjectingthe metal to the influence ofa relatively hi h voltage electric arc in an electric circuit 0 given kilowatt load, then reducing the voltage of said arc in said circuit while retaining substantially the same kilowatt i load, maintaining the..kilowatt load of said vcircuit; during both said steps substantially the same.

'5. The method of treating metal bythe use of an electric are, which consists in sub- 11 jecting the metal to the influence of a relatively high voltage and relatively long elec trio arc in an electric circuit of -given kilowatt load, then reducing the voltage of said are and the length of said are in said circuit while retaining substantially the same kilowatt load. a

6. The method of treating metal by the use of an electric are, which consists in subjecting the metal to the influence of a relatively high voltage electric arc in an electric circuit of'given kilowatt load, then reducing jecting the metal to the influence of a relativelv high voltave electric are in an planh-in Y1 an circuit for a period of time sufficient to effect the melting of the metal and then effecting the desired refining by reducing the voltage and increasing the amperage of the current flowing in the arc circuit.

8. The method of treating metal by the use of an electric arc, which consists in subjecting the metal to the influence of a relatively high voltage electric arc in an electric circuit for 'a period of time sufiicient to efiect the melting-of the metal and then effecting the desired refining by substantially simultaneously reducing the voltage and increasing the amperage of the current flowing in the arc circuit.

9. The method of treating metal by the use of anelectric arc,'wh'ich consists in subjecting the metal to the influence of a relatively high voltage and relatively long electric arc in an electric circuit, then reducing the voltage of said are and the length of said are and increasing the amperage of the current flowingin the arc circuit.

10. The method of treating metal by the use of anelectric arc, which consists in sub- .jecting the metal to the influence of a relatively high voltage and relatively long electric arc in an electric circuit, then substantially simultaneously reducing the voltage of said arc and the length of said are and increasing the amperage of the current flowing in the arc circuit.

11. The method of treating metal by the use of an electric are, which consists in subjecting the metal to the influence of a relatively high voltage electric arc in an electric circuit for a period oftime suflicient to effeet the melting of the metal and then effecting the desired refining by reducing the voltage and increasing the amperage of the current flowing in the 'arc circuit by transformer reactions therein.

-12. The method of treating metal by the "use of an electric arc, which consists in subjecting the metal to the influence of a relatively high voltage and relatively long electric. arcin an electric circuit, then reducing the voltage of said are and the length of said are and increasing the amperage of'the current flowing in the arc circuit by transformer reactions therein.

'In testimony whereof l' affixniy signature in thepresence of two witnesses.

REGINALD BULLEY. 'Witnesses:

" L. S. LoMMAssoN,

EDWARD T. MOORE. 

